Damage resistant decorative laminate having excellent appearance and cleanability and methods of producing same

Abstract

Damage resistant high pressure decorative laminate having excellent scratch, mar, scrape and abrasion resistance, as well as excellent appearance and cleanability and methods of producing same.

What is claimed is: 
     
       1. A binderless damage resistant decorative laminate having improved scratch, mar, scrape and abrasion resistance comprising at least one backing layer sheet and a thermoset resin impregnated paper sheet laminated thereto, said decorative paper sheet having thereon an abrasion resistant coating composed of a mixture consisting essentially of: (a) abrasion resistant mineral particles having a particle size of from about 15 microns to about 45 microns in a concentration of from about 8 to about 12 grams per square meter of surface area;   (b) a silane coupling agent in an amount dependant upon the concentration of the abrasion resistant mineral particles;   (c) a thickening agent in an amount sufficient to suspend said abrasion resistant particles; and   (d) a small but effective amount of polyethylene glycol stearate to enhance surface slip and improve scrape resistance of the laminate.   
     
     
       2. A binderless, damage resistant decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said thermoset resin is melamine-formaldehyde. 
     
     
       3. A damage resistant decorative laminate according to claim 2 wherein such polyethylene glycol stearate is present in amounts ranging from 0.05 to about 0.25 percent. 
     
     
       4. A binderless, damage resistant decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said abrasion resistant mineral particles are alumina. 
     
     
       5. A binderless, damage resistant decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said thickening agent is xanthan gum. 
     
     
       6. A damage resistant decorative laminate according to claim 5 wherein such xanthan gum is present in amounts ranging from about 0.05 to about 0.25 percent. 
     
     
       7. A binderless, damage resistant decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said laminate further comprises an additional coating of a resin formulation comprising abrasion resistant particles having a particle size of about 3 microns. 
     
     
       8. A binderless damage resistant decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said laminate further comprises an overlay sheet.